Protective Vehicle Battery Cage and Method of Making a Battery Cage

• US 20140147717A1
• Filed: 11/27/2012
• Published: 05/29/2014
• Est. Priority Date: 11/27/2012
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Sundararajan, Srinivasan, Wu, Fubang, Faruque, Mohammed Omar, Azzouz, Michael M., Van Dyk, Sino Johan
• Granted Patent: US 9,236,592 B2
• Time in Patent Office: Days
• US Class Current: 429/99
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60R 16/04 Arrangement of batteries
• CPC Class Codes: B62D 21/02 comprising longitudinally or transversely arranged frame members
• CPC Class Codes: B62D 21/06 of X-shaped or fork-shaped construction, i.e. having members which form an X or fork as the frame is seen in plan view
• CPC Class Codes: B62D 23/005 with integrated chassis in the whole shell, e.g. meshwork, tubes, or the like B62D33/044 takes precedence
• CPC Class Codes: H01M 2200/00 Safety devices for primary or secondary batteries
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/262 with fastening means, e.g. locks
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 29/49947 by applying separate fastener

Abstract

A cage assembly is provided to protect a battery pack in a vehicle. The cage assembly includes a top sub-assembly and a bottom sub-assembly that are secured together to protect the battery pack. U-shaped frames and base frames are connected together by tubular members.

Claims

1. A cage for a battery pack comprising:

a top sub-assembly includes a first plurality of tubes that are spaced apart and a plurality of spaced inverted U-shaped frames that have a frame height corresponding to a battery height; and

a lower sub-assembly including a second plurality of tubes that are spaced apart and a plurality of spaced frames having a height that is less than the frame height, and is assembled to the top sub-assembly.

2. The cage for the battery pack of claim 1 wherein the inverted U-shaped frames define a plurality of openings that each receive one of the first plurality of tubes.

3. The cage for the battery pack of claim 1 wherein the spaced frames of the lower sub-assembly each define a plurality of openings that each receive one of the second plurality of tubes.

4. The cage for the battery pack of claim 1 wherein the spaced inverted U-shaped frames have a pair of upper feet that extend outwardly from a pair of lower ends of the U-shaped frames, and wherein the spaced frames of the lower sub-assembly each have lower feet that extend outwardly from the spaced frames at locations corresponding to the upper feet, and wherein the upper feet are assembled to the lower feet with fasteners.

5. The cage for the battery pack of claim 1 wherein the lower sub-assembly further comprises a pan that is framed by a portion of the tubes and the spaced frames of the lower sub-assembly.

6. The cage for the battery pack of claim 1 wherein the first plurality of tubes includes a first set of longitudinally extending tubes and a first set of transversely extending tubes, and the second plurality of tubes includes a first set of longitudinally extending tubes and a second set of transversely extending tubes, wherein the first set of longitudinally extending tubes and the second set of longitudinally extending tubes are assembled to a longitudinally extending tunnel in a floor pan of a vehicle and the first set of transversely extending tubes and the second set of transversely extending tubes are assembled to a transversely extending tunnel formed in the floor pan of the vehicle.

7. The cage for the battery pack of claim 1 wherein the U-shaped frames of the top sub-assembly and the spaced frames of the lower sub-assembly are castings.

8. The cage for the battery pack of claim 1 wherein the U-shaped frames of the top sub-assembly and the spaced frames of the lower sub-assembly are extruded parts.

9. The cage for the battery pack of claim 1 in combination with the battery pack further comprises a plurality of battery cells, and wherein the top sub-assembly and lower sub-assembly are assembled together on opposite sides of the battery cells.

10. The cage for the battery pack in combination with the battery pack of claim 9 further comprising a damper disposed between the battery cells and the top sub-assembly and lower sub-assembly, wherein the damper is a resilient foam pad.

11. A method of making a cage for a battery pack of a vehicle comprising:

assembling a first plurality of spaced tubes that and a plurality of spaced inverted U-shaped frames to from a first sub-assembly; and

assembling a second plurality of spaced tubes and a plurality of spaced frames to form a second sub-assembly; and

assembling the first sub-assembly and the second sub-assembly together to enclose the battery pack.

12. The method of making the cage for the battery pack of claim 11 further comprising:

welding the first plurality of spaced tubes to the plurality of spaced inverted U-shaped frames; and

welding the second plurality of spaced tubes to the plurality of spaced frames.

13. The method of making the cage for the battery pack of claim 11 further comprising:

extruding the first and second plurality of spaced tubes.

14. The method of making the cage for the battery pack of claim 11 further comprising:

extruding the U-shaped frames; and

extruding the spaced frames.

15. The method of making the cage for the battery pack of claim 11 further comprising:

casting the U-shaped frames; and

casting the spaced frames.

16. The method of making the cage for the battery pack of claim 11 further comprising:

bolting the first sub-assembly to the second sub-assembly.

17. The method of making the cage for the battery pack of claim 11 further comprising:

inserting a damper between the battery pack and the second sub-assembly.